Electrical splice connector

BACKGROUND

0001Electric cables are broadly employed in a variety of industries and applications, including applications in communications, telecommunications, automotive, and/or appliances. Some electrical cables distribute power across vast power grids or networks, moving electricity from power generation plants to the consumers of electrical power, and moving electricity from one power grid to another power grid. Other electrical cables are employed in wiring homes and/or businesses.

0002Electrical cables generally include a conductive core (typically copper or aluminum) and may include one or more layers of surrounding insulating material. Some power cables include multiple twisted conductive wires. Electrical cables are constructed to carry high voltages (greater than about 50,000 volts), medium voltages (between about 1,000 volts and about 50,000 volts), or low voltages (less than about a 1,000 volts).

0003It is sometimes desirable to periodically form a splice or a junction in the cable, for example to electrically connect two electrical devices or to distribute electricity to additional branches of a power grid. Such branches may be further distributed until the grid reaches individual homes, businesses, offices. As one example, a single power cable supplying electrical power to a group of several buildings is commonly branched to each of the buildings. As used in this specification, the terms “splice” and “junction” are used interchangeably, and in each case refer to the portion of an electrical system where an incoming cable is connected to at least one outgoing cable.

0004Connecting incoming cables with one or more outgoing cables can potentially result in heating the cables at the junction, or heating the electrical connector employed to form the junction. It is desirable to quickly and conveniently form the splice in a manner that is configured to minimize electrical heating of the cables.

0005For these and other reasons, there is a need for the present invention.

SUMMARY

0006Embodiments according to the invention provide an electrical splice connector. The electrical splice connector includes a housing, a conductive member retained within the housing and defining a longitudinal axis, and at least two biasing members circumferentially disposed about the longitudinal axis of the conductive member and biased toward the conductive member. Each of the biasing members is configured to urge conductors inserted into the housing into electrical contact with the conductive member.

BRIEF DESCRIPTION OF THE DRAWINGS

0007The accompanying drawings are included to provide a further understanding of embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.

0008<figref idref="DRAWINGS">FIG. 1A</figref> is an exploded perspective view of an electrical splice connector according to one embodiment.

0009<figref idref="DRAWINGS">FIG. 1B</figref> is a sectional view of the electrical splice connector shown in <figref idref="DRAWINGS">FIG. 1A</figref> as assembled.

0010<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of the electrical splice connector of <figref idref="DRAWINGS">FIG. 1A</figref> as assembled.

0011<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of the assembled electrical splice connector shown in <figref idref="DRAWINGS">FIG. 2</figref>.

0012<figref idref="DRAWINGS">FIG. 4A</figref> is a cross-sectional view of the assembled electrical splice connector shown in <figref idref="DRAWINGS">FIG. 2</figref> including a first conductor inserted into a first end of the splice connector and a second conductor inserted into a second end of the splice connector.

0013<figref idref="DRAWINGS">FIG. 4B</figref> is a cross-sectional view of another electrical connector including means for removing inserted conductor shown in <figref idref="DRAWINGS">FIG. 4A</figref>.

0014<figref idref="DRAWINGS">FIG. 5</figref> is a front view of one end cap of the electrical splice connector shown in <figref idref="DRAWINGS">FIG. 1</figref>.

0015<figref idref="DRAWINGS">FIG. 6</figref> is a front view of the other end cap of the electrical splice connector shown in <figref idref="DRAWINGS">FIG. 1</figref>.

0016<figref idref="DRAWINGS">FIG. 7A</figref> is a perspective view of a spring member of the electrical splice connector shown in <figref idref="DRAWINGS">FIG. 1A</figref> according to one embodiment.

0017<figref idref="DRAWINGS">FIG. 7B</figref> is a perspective view of a bell-shaped biasing member according to another embodiment.

0018<figref idref="DRAWINGS">FIG. 8</figref> is a perspective view of a spring member according to another embodiment.

0019<figref idref="DRAWINGS">FIG. 9</figref> is a perspective view of a spring member according to another embodiment.

0020<figref idref="DRAWINGS">FIG. 10</figref> is a perspective view of a spring member including teeth according to another embodiment.

0021<figref idref="DRAWINGS">FIG. 11</figref> is a cross-sectional view of an electrical splice connector according to another embodiment.

0022<figref idref="DRAWINGS">FIG. 12A</figref> is a perspective view of an electrical connector according to another embodiment.

0023<figref idref="DRAWINGS">FIG. 12B</figref> is an end view of the electrical connector shown in <figref idref="DRAWINGS">FIG. 12A</figref>.

DETAILED DESCRIPTION

0024In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

0025It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise.

0026Embodiments provide an electrical splice connector including two or more biasing members that are configured to urge a conductor into electrical contact with a conductive member of the electrical splice connector. In one embodiment, the electrical splice connector includes a cylindrical housing disposed around a cylindrical conductive member that is in turn disposed around at least two biasing members that are each configured to bias conductors inserted into the housing into electrical contact with the conductive member.

0027The cylindrical housing and conductive member are configured to provide improved heat dissipation and minimize undesirable overheating of the connector spliced between two conductors.

0028Embodiments provide an electrical splice connector configured to electrically connect conductors/wires having a wide range of conductor sizes. In one embodiment, an electrical splice connector is provided that electrically connects conductors, such as wires in a residential dwelling, having a size ranging from 10 gauge solid to 18 gauge stranded wire. Other embodiments provide an electrical splice connector suited for electrically connecting telecom, automotive, or industrial-sized conductors.

0029<figref idref="DRAWINGS">FIG. 1A</figref> is an exploded perspective view and <figref idref="DRAWINGS">FIG. 1B</figref> is an assembled section view of an electrical splice connector <b>20</b> according to one embodiment. Electrical splice connector <b>20</b> includes a housing <b>22</b>, a conductive member <b>24</b> retained within housing <b>22</b>, two biasing members <b>30</b>, <b>32</b> circumferentially disposed within conductive member <b>24</b>, and opposing end caps <b>26</b>, <b>28</b>. Conductive member <b>24</b> defines a longitudinal axis A. Biasing members <b>30</b>, <b>32</b> are disposed about longitudinal axis A of conductive member <b>24</b> and are outwardly biased toward conductive member <b>24</b>. Biasing members <b>30</b>, <b>32</b> are configured to urge conductors (not shown) inserted into housing <b>22</b> into electrical contact with conductive member <b>24</b>.

0030In one embodiment, conductive member <b>24</b> is retained within housing <b>22</b> between a first end cap <b>26</b> and an opposing end cap <b>28</b>. In one embodiment, a rod <b>34</b> is provided that extends between end caps <b>26</b>, <b>28</b> to support biasing members <b>30</b>, <b>32</b> circumferentially within conductive member <b>24</b>. In another embodiment, rod <b>34</b> is optional and biasing member <b>30</b> is coupled to end cap <b>26</b> and biasing member <b>32</b> is coupled to end cap <b>28</b>.

0031In one embodiment, housing <b>22</b> includes a substantially cylindrical housing having a wall <b>40</b> extending between a first end <b>42</b> and an opposing second end <b>44</b>, where wall <b>40</b> defines an interior surface <b>46</b>. In one embodiment, housing <b>22</b> defines a central diameter D<b>1</b> extending between opposing sides of interior surface <b>46</b> and a larger diameter D<b>2</b> adjacent to each end <b>42</b>, <b>44</b> configured to receive respective end caps <b>26</b>, <b>28</b>. In this manner, housing <b>22</b> defines a hollow housing that is flared at ends <b>42</b>, <b>44</b> to step up from central diameter D<b>1</b> to larger diameter D<b>2</b> adjacent ends <b>42</b>, <b>44</b>.

0032In this specification, the term “cylindrical” means any body defined by a longitudinal axis and a wall that defines an exterior surface, and includes circular cylinders, non-circular cylinders, solid cylinders, and hollow cylinders. The peripheral shape of a cross-section of the wall thus includes circular shapes, non-circular shapes, polygonal shapes, and other geometric shapes. Thus, a cylindrical housing or member is not limited to housings or members having circular shapes in cross-section, and includes polygonal shapes that approximate a cylinder.

0033Suitable materials for housing <b>22</b> include plastics such as thermoplastics, thermoset plastics, curable plastics, molded plastics, and other suitable electrical non-conductive materials including non-plastic materials. In one embodiment, housing <b>22</b> is formed of polycarbonate and is translucent or transparent to enable optical viewing of electrical connections made within housing <b>22</b>. Other suitable materials for forming housing <b>22</b> are also acceptable. In another embodiment, housing <b>22</b> is configured to provide high rates of heat transfer, which can be useful when connecting high voltage conductors. Suitable high heat transfer housings <b>22</b> include housings formed of a plastic filled with metal, such a polycarbonate filled with aluminum trihydroxide particles, or housings formed of a composition of a metal filled with plastic particles.

0034In one embodiment, conductive member <b>24</b> includes a substantially cylindrical conductive member disposed within housing <b>22</b>. In one embodiment, substantially cylindrical conductive member <b>24</b> defines a hollow member having an exterior surface <b>70</b> that is disposed immediately adjacent to interior surface <b>46</b> of cylindrical wall <b>40</b> and an interior surface <b>72</b> opposite exterior surface <b>70</b>. In one embodiment, conductive member <b>24</b> is press-fit within cylindrical housing <b>22</b>. In another embodiment, conductive member <b>24</b> is disposed within housing <b>22</b> and retained in place by end caps <b>26</b>, <b>28</b>.

0035Suitable materials for conductive member <b>24</b> include electrically conductive materials, one example of which is metal. In one embodiment, conductive member <b>24</b> is fabricated from copper, alloys of copper, aluminum, alloys of aluminum, bronze, nickel, alloys of nickel, or other suitable electrically conducting materials including non-metallic conducting materials. In one embodiment, conductive member <b>24</b> is a substantially cylindrical member formed of brass including a tin plating.

0036End caps <b>26</b>, <b>28</b> are generally formed of electrically non-conductive material and are configured to couple to one of the respective ends <b>42</b>, <b>44</b> of housing <b>22</b>. In one embodiment, end caps <b>26</b>, <b>28</b> are configured to snap into a respective end <b>42</b>, <b>44</b> of housing <b>22</b>. In other embodiments, end caps <b>26</b>, <b>28</b> are threaded, welded, glued, or friction-fit onto a respective end <b>42</b>, <b>44</b> of housing <b>22</b>.

0037In one embodiment, end cap <b>26</b> provides a plurality of openings <b>50</b> including a first opening <b>52</b>, a second opening <b>54</b>, and a third opening <b>56</b>. Other suitable numbers for the plurality of openings <b>50</b> formed in end cap <b>26</b> are also acceptable such as one opening, two openings, or four or more openings. In one embodiment, end cap <b>28</b> defines a plurality of openings <b>60</b> including a first opening <b>62</b> and a second opening <b>64</b>. Other numbers for the plurality of openings <b>60</b> of second end cap <b>28</b> are also acceptable, including one opening, three openings, or four or more openings.

0038In one embodiment, biasing member <b>30</b> is provided separately from biasing member <b>32</b>. In another embodiment, biasing member <b>30</b> and biasing member <b>32</b> are attached by rod <b>34</b> and provided as an assembly. In one embodiment, biasing member <b>30</b> is a conical spring and is substantially identical to biasing member <b>32</b>. In another embodiment, biasing member <b>30</b> is different from biasing member <b>32</b>, for example, being formed of a different material, having different diameters, different leaf lengths, etc.

0039In this specification, the term “conical” includes cones, polygonal shapes that approximate a cone, multi-sided members that approximate a funnel-shape, members that approximate a bell-shape, and similar such shapes that are truncated by removing an apex of a conical shape, resulting in a frustum having a plane defined by the removed apex that is approximately parallel to a base of the conical shape.

0040In general, biasing members <b>30</b>, <b>32</b> are configured to provide a biasing force outward in the direction of conductive member <b>24</b> (i.e., generally transverse to axis A) such that a conductor (not shown) inserted into one of the plurality of openings <b>50</b>, <b>60</b> is forced into electrical contact with conductive member <b>24</b>. In one embodiment, the inserted conductor has a size of between about 10-20 gauge and the biasing force of biasing members <b>30</b>, <b>32</b> is configured to enable easy insertion of the conductor into housing <b>22</b> (e.g., insertion by hand) in combination with a relatively large pull-out force (e.g., about 15 pounds) selected to hold the conductor in electrical contact with conductive member <b>24</b>. In one embodiment, the biasing force for biasing members <b>30</b>, <b>32</b> is configured such that an inserted conductor cannot be removed from housing <b>22</b> without destructively breaking one or both of connector <b>20</b> or the inserted conductor.

0041Suitable materials for biasing members <b>30</b>, <b>32</b> include metals and other electrically conductive materials. In one embodiment, biasing members <b>30</b>, <b>32</b> are formed from spring steel, stainless steel, bronze, or copper into a substantially conical spring. In one embodiment, each biasing member <b>30</b>, <b>32</b> is formed of heat treatable steel such as <b>410</b> stainless steel, although other metals, metal-coated plastics, or plastics are also acceptable depending upon the end-use application. Biasing members <b>30</b>, <b>32</b> are suitably fabricated by die cutting, stamping, drawing, annealing, and/or punching.

0042<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of electrical splice connector <b>20</b> as assembled. In one embodiment, first end cap <b>26</b> defines projections <b>80</b> (one shown) that are configured to snap-fit into a corresponding slots provided by housing <b>22</b>, and second end cap <b>28</b> defines projections <b>82</b> (one shown) configured to snap-fit into other corresponding slots provided by housing <b>22</b>. The plurality of openings <b>50</b> formed by first end cap <b>26</b> and the plurality of openings <b>60</b> formed by second end cap <b>28</b> provide conductor receiver openings <b>52</b>, <b>54</b>, <b>56</b>, and <b>62</b>, <b>64</b>, respectively, that communicate with an interior of housing <b>22</b>.

0043<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of the assembled electrical splice connector <b>20</b>. Conductive member <b>24</b> is inserted into housing <b>22</b> such that exterior surface <b>70</b> of conductive member <b>24</b> is substantially contiguous with interior surface <b>46</b> of housing <b>22</b>. Placement of conductive member <b>24</b> against housing <b>22</b> configures electrical splice connector <b>20</b> for improved heat transfer. For example, in one embodiment housing <b>22</b> and conductive member <b>24</b> combine to effectively dissipate heat generated by the electrically connected conductors inserted into housing <b>22</b>. Other embodiments provide conductive member <b>24</b> offset a distance from housing <b>22</b>.

0044In general, biasing members <b>30</b>, <b>32</b> are circumferentially disposed within conductive member <b>24</b>. In one embodiment, an inner surface <b>85</b> of first end cap <b>26</b> defines a relief <b>86</b> sized to receive a small end <b>87</b> of conical biasing member <b>30</b>, and an inner surface <b>95</b> of second end cap <b>28</b> defines a relief <b>93</b> sized to receive a small end <b>97</b> of conical biasing member <b>32</b>. In one embodiment, rod <b>34</b> is a free-floating rod <b>34</b> that extends between first end cap <b>26</b> and second end cap <b>28</b> to maintain biasing member <b>30</b> against cap <b>26</b> and biasing member <b>32</b> against cap <b>28</b>.

0045In another embodiment, biasing member <b>30</b> is coupled to one end of rod <b>34</b> and second biasing member <b>32</b> is coupled to an opposing end of rod <b>34</b>, and rod <b>34</b> extends between end caps <b>26</b>, <b>28</b> such that biasing member <b>30</b> is disposed adjacent to first end cap <b>26</b> and second biasing member <b>32</b> is disposed adjacent to second end cap <b>28</b>. Other structures for circumferentially disposing biasing members <b>30</b>, <b>32</b> within conductive member <b>24</b>, and other relative locations for biasing members <b>30</b>, <b>32</b> are also acceptable.

0046When electrical splice connector <b>20</b> is configured for larger gauge conductors (i.e., conductors having smaller diameters), biasing members <b>30</b>, <b>32</b> are configured to expand outward to contact conductive member <b>24</b>. When electrical splice connector <b>20</b> is configured for smaller gauge conductors (i.e., conductors having larger diameters), biasing members <b>30</b>, <b>32</b> are configured to provide an offset space between biasing members <b>30</b>, <b>32</b> and conductive member <b>24</b>, where the offset space is selected to reduce the insertion force for the inserted conductors.

0047<figref idref="DRAWINGS">FIG. 4A</figref> is a cross-sectional view of electrical splice connector <b>20</b> including a first conductor <b>90</b> inserted into opening <b>54</b> and a second conductor <b>92</b> inserted into opening <b>64</b>. In one embodiment, conductor <b>90</b> is an insulated conductor including insulation <b>94</b>, a portion of which is removed to define a conductive end portion <b>96</b>. Conductor <b>92</b> is similar to conductor <b>90</b> and includes a conductive end portion <b>98</b>. In other embodiments, conductors <b>90</b>, <b>92</b> do not include insulation.

0048Biasing members <b>30</b>, <b>32</b> are configured to bias or otherwise deflect conductive end portions <b>96</b>, <b>98</b>, respectively, into electrical contact with conductive member <b>24</b>. With additional reference to <figref idref="DRAWINGS">FIG. 2</figref>, in one embodiment conductor <b>90</b> is insertable into any one of the plurality of openings <b>50</b> defined by first end cap <b>26</b> and biasing member <b>30</b> is configured to bias conductive end portion <b>96</b> into electrical contact with interior surface <b>72</b> of conductive member <b>24</b>. In a similar manner, conductor <b>92</b> is insertable into any one of plurality of openings <b>60</b> formed by second end cap <b>28</b> such that conductive end portion <b>98</b> is forced into electrical contact with interior surface <b>72</b> of conductor member <b>24</b>.

0049In one embodiment, biasing members <b>30</b>, <b>32</b> are configured to provide an outward biasing force that presses conductive end portions <b>96</b>, <b>98</b> against conductive member <b>24</b> such that conductors <b>90</b>, <b>92</b>, respectively, cannot be removed from electrical splice connector <b>20</b> without deforming or destructing one or both of connectors <b>90</b>/<b>92</b> and/or electrical splice connector <b>20</b>.

0050It is desirable that conductors <b>90</b>, <b>92</b> are insertable into electrical splice connector <b>20</b> without undesirable twisting motions, which can potentially column buckle conductors <b>90</b>, <b>92</b>. In one embodiment, biasing members <b>30</b>, <b>32</b> include segmented leaf springs that enable conductors <b>90</b>, <b>92</b> to be directly (i.e., linearly) pushed inward into electrical splice connector <b>20</b> without undesired twisting of conductors <b>90</b>, <b>92</b>. In another embodiment, multiple biasing members are disposed on bilateral sides of electrical splice connector <b>20</b> as described below to achieve a desired force to bias connective end portions <b>96</b>, <b>98</b> of small gauge conductors into electrical connection with conductive member <b>24</b>.

0051<figref idref="DRAWINGS">FIG. 4B</figref> is a cross-sectional view of an electrical connector <b>20</b>′ including means for removing inserted conductor <b>92</b>. In one embodiment, housing <b>22</b>′ and conductive member <b>24</b>′ each define a slot <b>25</b> that combine to provide a passageway for a tool <b>27</b> to enter connector <b>20</b>′. Tool <b>27</b> is configured to deflect biasing member <b>32</b>, for example, thus relieving the biasing stress applied by biasing member <b>32</b> toward conductive member <b>24</b>′, to enable removal of conductor <b>92</b>. For example, embodiments provide slot <b>25</b> sized to receive a flat-blade screwdriver or similar device that may be employed to displace biasing member <b>32</b> a distance sufficient to relieve the force that the biasing member <b>32</b> applies to conductor <b>92</b>. In other embodiments, a passageway is provided in one or both end caps <b>26</b>, <b>28</b> (<figref idref="DRAWINGS">FIG. 1A</figref>) to enable tool <b>27</b> to enter housing <b>22</b>′ parallel to inserted conductor <b>92</b> and relieve the biasing stress applied by biasing member <b>32</b> toward conductive member <b>24</b>′.

0052<figref idref="DRAWINGS">FIG. 5</figref> is a front view of first end cap <b>26</b> and <figref idref="DRAWINGS">FIG. 6</figref> is a front view of second end cap <b>28</b>. In one embodiment, first end cap <b>26</b> defines three conductor receiver openings <b>52</b>, <b>54</b>, <b>56</b> and second end cap <b>28</b> defines two conductor receiver openings <b>62</b>, <b>64</b>. In general, first and second end caps <b>26</b>, <b>28</b> define at least one conductor receiver opening. The number of openings in each end cap <b>26</b>, <b>28</b> can be the same or different depending upon an end use for electrical splice connector <b>20</b>. In one embodiment, a plurality of end caps is provided, where each end cap has a different number of conductor receiver openings, and an installer or electrician selects a desired end cap to be releasably coupled to an end of housing <b>22</b> (<figref idref="DRAWINGS">FIG. 1</figref>). Each opening in the plurality of openings <b>50</b>, <b>60</b> is configured to direct an inserted conductor into electrical contact with conductive member <b>24</b> (<figref idref="DRAWINGS">FIG. 1</figref>).

0053In one embodiment, a kit of parts is provided that includes electrical splice connector <b>20</b> and a plurality of end caps <b>26</b> and <b>28</b>, where the plurality of end caps includes at least two end caps each defining at least one conductor receiver opening and at least one end cap <b>26</b>, <b>28</b> defining at least two conductor receiver openings. The user can then select the end caps having the desired number of receiver openings for that particular installation application.

0054<figref idref="DRAWINGS">FIG. 7A</figref> is a perspective view of conical biasing member <b>30</b>. In one embodiment, biasing member <b>32</b> (<figref idref="DRAWINGS">FIG. 1</figref>) is similar to biasing member <b>30</b> such that the following description applies equally to biasing member <b>32</b>.

0055In one embodiment, biasing member <b>30</b> is funnel-shaped and includes a first end <b>100</b> that defines a first diameter D<b>3</b> and a second end <b>102</b> that defines a second diameter D<b>4</b> that is larger than first diameter D<b>3</b>. In one embodiment, biasing member <b>30</b> provides a conical spring having a plurality of segmented leafs <b>104</b> defined by relief slots <b>106</b> that extend from second end <b>102</b> toward first end <b>100</b>. Leafs <b>104</b> are flexible and configured to bias in a radial direction such that biasing member <b>30</b> has attributes of a living spring. In one embodiment, one relief slot <b>106</b><i>a </i>extends an entire length between first end <b>100</b> and second end <b>102</b> to configure conical leaf spring <b>30</b> to flexibly accommodate a wide range of conductor sizes.

0056<figref idref="DRAWINGS">FIG. 7B</figref> is a perspective view of another form of a conical biasing member <b>108</b> according to one embodiment. In one embodiment, biasing member <b>108</b> is bell-shaped and includes a first end <b>109</b> that defines a first diameter and a second end <b>110</b> that defines a second diameter that is larger than first diameter. In one embodiment, biasing member <b>108</b> provides a conical spring having a plurality of segmented leafs <b>111</b> defined by relief slots <b>112</b> that extend from second end <b>110</b> toward first end <b>100</b>. In one embodiment, leafs <b>111</b> include openings <b>113</b> configured to adjust a biasing force applied by leafs <b>111</b>.

0057<figref idref="DRAWINGS">FIG. 8</figref> is a perspective view of a conical biasing member <b>118</b> according to another embodiment. Biasing member <b>118</b> includes a first end <b>120</b> and a second end <b>122</b>, where second end <b>122</b> has a diameter that is larger than first end <b>120</b> such that biasing member <b>118</b> is funnel-shaped. Biasing member <b>118</b> includes segmented leafs <b>124</b> defined by relief slots <b>126</b> that extend from second end <b>122</b> toward first end <b>120</b>.

0058In one embodiment, leafs <b>124</b> include a channel <b>128</b> formed between two relief slots <b>126</b>. Channel <b>128</b> is configured to receive conductive end portion <b>96</b> (<figref idref="DRAWINGS">FIG. 4A</figref>) of conductor <b>90</b>. In one embodiment, channel <b>128</b> is configured to enable biasing member <b>118</b> to guide/support smaller diameter (18-20 gauge) conductors, and in particular smaller diameter twisted wire conductors, enabling the smaller diameter conductors to be inserted into electrical splice connector <b>20</b> as described herein without undesirable buckling of the conductor <b>90</b>.

0059<figref idref="DRAWINGS">FIG. 9</figref> is a perspective view of a conical biasing member <b>138</b> according to another embodiment. Biasing member <b>138</b> includes a first end <b>140</b> and a second end <b>142</b> opposite first end <b>140</b>. Biasing member <b>138</b> defines a conical spring member having a diameter at second end <b>142</b> that is larger than a diameter at first end <b>140</b>. In one embodiment, biasing member <b>138</b> includes a plurality of leafs <b>144</b> defined by relief slots <b>146</b> that extend from second end <b>142</b> toward first end <b>140</b>. In one embodiment, leafs <b>144</b> are polygonal in shape and are connected one to another along first end <b>140</b> such that conical biasing member <b>138</b> is non-circular in cross-section at first end <b>140</b> and second end <b>142</b>.

0060<figref idref="DRAWINGS">FIG. 10</figref> is a perspective view of a conical biasing member <b>158</b> according to another embodiment. Biasing member <b>158</b> includes a first end <b>160</b>, a second end <b>162</b>, and leafs <b>164</b> defined by relief slots <b>166</b> that extend from second end <b>162</b> toward first end <b>160</b>. In one embodiment, leafs <b>164</b> include teeth <b>170</b> formed at second end <b>162</b>. Teeth <b>170</b> are configured to engage with conductive end portion <b>96</b> of conductor <b>90</b> (<figref idref="DRAWINGS">FIG. 4A</figref>) to securely retain conductor <b>90</b> within electrical splice connector <b>20</b> (<figref idref="DRAWINGS">FIG. 4A</figref>). In one embodiment, teeth <b>170</b> are configured to remove, scratch through, or uncover oxidation formed on conductive end portion <b>96</b> to ensure electrical connection with conductive end portion <b>96</b>.

0061With reference to <figref idref="DRAWINGS">FIG. 1</figref>, biasing member <b>30</b> includes any one of biasing members <b>32</b>, <b>108</b>, <b>118</b>, <b>138</b>, or <b>158</b> described herein, and biasing member <b>32</b> includes any one of biasing members <b>30</b>, <b>108</b>, <b>118</b>, <b>138</b>, or <b>158</b> described herein, where biasing member <b>30</b> is the same or different from biasing member <b>32</b>.

0062<figref idref="DRAWINGS">FIG. 11</figref> is a cross-sectional view of an electrical splice connector <b>200</b> according to another embodiment. Electrical splice connector <b>200</b> includes a housing <b>202</b>, a conductive member <b>204</b> retained within housing <b>202</b>, a first pair <b>206</b> of biasing members disposed within conductive member <b>204</b>, and a second pair <b>208</b> of biasing members disposed within conductive member <b>204</b> about a central longitudinal axis of conductive member <b>204</b>. In one embodiment, an interior volume of conductive member <b>204</b> optionally includes sealant <b>209</b>. Sealant <b>209</b> is configured prevent the ingress of moisture, dust, insects, or other debris into electrical splice connector <b>200</b>. In one embodiment, sealant <b>209</b> is selected and configured to minimize or eliminate oxidation of metal portions of conductive member <b>204</b>, first and second pairs <b>206</b>, <b>208</b> of biasing members, and conductors/wires inserted into electrical splice connector <b>200</b>.

0063In one embodiment, sealant <b>209</b> is a hydrophobic sealant, examples of which includes gel sealants or grease sealants. In general, gel sealant <b>209</b> includes soft rubbers and gels having shape memory. Gel sealant <b>209</b> is typically formed from at least one polymer in combination with at least one oil. The oil provides an extender for the gel sealant and includes hydrocarbon oil, such as naphthinic oils, paraffinic oils, aromatic oils, silicone oil, or vegetable ester oil, or a plasticizer such as phthalate ester oils. In one embodiment, gel sealant <b>209</b> includes multiple extenders and polymers, including extenders and polymers intermediate between oil and polymer. In one embodiment, gel sealant <b>209</b> includes a liquid rubber that is not part of the gel forming polymer network, such as polybutene of moderate molecular weight or a low molecular weight ethylene propylene rubber (EPR). These materials, in combination, are configured to tailor characteristics of the gel sealant <b>209</b> by increasing tack, for example.

0064The polymer-based gel can be either a thermoplastic or cured in place. The curing includes thermal curing, room temperature vulcanization, ultraviolet curing, e-beam curing, or other radiation initiated curing. It is desirable that the polymer be compatible with oil, and can include a rubber-like morphology, having flexible chains with molecular flexibility between cross-linking sites. Suitable polymers include polyurethanes, polyesters, polyepoxys, polyacrylates, polyolefins, polysiloxanes, polybutadienes (including polyisoprenes), hydrogenated polybutadienes and polyisoprenes, or block copolymers. The blocks of the block copolymers may include the above-identified polymers, and/or poly(monoalkenylarenes) including polystyrene. Suitable block copolymers include styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), styrene-rubber-styrene polymers, di-block polymers, tri-block polymers, graft and star-block copolymers, or block copolymers with blocks that are non-homogeneous. Other suitable materials include closed-cell foamed materials, and materials incorporating micro-bubbles or soft (or hard) fillers.

0065Sealant <b>209</b> includes grease sealants. A grease is defined to be viscoelastic hydrophobic composition including 50-95% hydrocarbon oil, such as naphthinic oils or paraffinic oils and/or blends, aromatic oils, silicone oils, vegetable oils, or plasticizer oils such as phthalates. Greases are hydrophobic liquids at room temperature and include a low volatility such that they do not experience appreciable loss of mass after a long duration exposure to high operating temperatures. Some grease includes agents to provide the mechanical properties of low shear yield point and higher adhesion than cohesion. Desirable additives to grease include inorganic materials, including molybdenum sulfide, silica gels (including silica gels including a surface treatment control agglomeration) lithium compounds, soaps, waxes including polyethylene and polypropylene waxes, polymers including polyurethanes, polyesters, polyepoxys, polyacrylates, polyolefins, polysiloxanes, polybutadienes (including polyisoprenes), hydrogenated polybutadienes and polyisoprenes, or block copolymers. The blocks of the block copolymers may include the above identified polymers and poly(monoalkenylarenes) including polystyrene. Suitable block copolymers include SEB, SEP, SEBS, SEPS, Styrene-rubber polymers, di-block polymers, graft and star-block copolymers, or block copolymers with blocks that are non-homogeneous. In one embodiment, grease sealant <b>209</b> includes a grease sealant prepared from shearing a gel, as is disclosed in U.S. Pat. Nos. 5,292,058, 5,286,516, 5,418,001 or 5,601,668.

0066Conductive member <b>204</b> is retained within housing <b>202</b> between a first end cap <b>210</b> and an opposing second end cap <b>212</b>. In one embodiment, first end cap <b>210</b> defines an end post <b>214</b> configured to support first pair <b>206</b> of biasing members, and second end cap <b>212</b> defines an end post <b>216</b> configured to support second pair <b>208</b> of biasing members.

0067In another embodiment, the biasing members are retained within conductive member <b>204</b> in which an inner surface of first end cap <b>210</b> defines a relief sized to receive a small end of one of the conical biasing members in pair <b>206</b>, and an inner surface of second end cap <b>212</b> defines a relief sized to receive a small end of one of the conical biasing members in pair <b>208</b>, in a manner similar to <figref idref="DRAWINGS">FIG. 3</figref>. In one embodiment, posts <b>214</b>, <b>216</b> are formed as a single post that extends continuously and free-floats between first end cap <b>210</b> and second end cap <b>212</b> to retain the pairs <b>206</b>, <b>208</b> of biasing members.

0068First pair <b>206</b> of biasing members includes a first biasing member <b>220</b> and a second biasing member <b>222</b>, where biasing members <b>220</b>, <b>222</b> individually include any of biasing members <b>30</b>, <b>108</b>, <b>118</b>, <b>138</b>, or <b>158</b> described herein. Second pair <b>208</b> of biasing members includes a first biasing member <b>230</b> and a second biasing member <b>232</b>, where biasing members <b>230</b>, <b>232</b> individually include any of biasing members <b>30</b>, <b>108</b>, <b>118</b>, <b>138</b>, or <b>158</b> described herein.

0069In one embodiment, housing <b>202</b> is similar to housing <b>22</b> described above and includes a plastic or other non-electrically conductive housing, and conductive member <b>204</b> is similar to conductive member <b>24</b> described above and is formed of a suitable electrically conducting material. Conical biasing members <b>220</b>, <b>222</b> and <b>230</b>, <b>232</b> are biased toward conductive member <b>204</b> and are configured to urge conductors (not shown) inserted into housing <b>202</b> into electrical contact with conductive member <b>204</b>.

0070The multiple conical biasing members provided by first and second pairs <b>206</b>, <b>208</b> of biasing members are configured to provide a sufficiently high outward radial force against inserted conductors (not shown) such that the inserted conductors (even large diameter conductors of about 10 gauge) cannot be removed from housing <b>202</b> without applying a pulling force to the conductors of greater than about 15 pounds. In some embodiments, more than two biasing members are employed adjacent to each end cap <b>210</b>, <b>212</b> side to selectively vary the level of conductor removal force.

0071In one embodiment, an optional boots <b>250</b> and/or <b>252</b> are provided. Boot <b>250</b> is configured to seal end cap <b>210</b>, and boot <b>252</b> is configured to seal end cap <b>212</b>. Boots <b>250</b>, <b>252</b> each include openings that correspond to openings provided in end caps <b>210</b>, <b>212</b>. In one embodiment, each boot <b>250</b>, <b>252</b> is formed of a thermoplastic elastomer and includes “self-sealing” openings that are configured to close to limit entry of dust and debris into housing <b>202</b> and configured to seal over a conductor inserted into end caps <b>210</b>, <b>212</b>.

0072In one embodiment, boots <b>250</b>, <b>252</b> are configured to constrain and/or retain sealant (<b>209</b> in <figref idref="DRAWINGS">FIG. 11</figref>) provided on an interior (e.g., within) boots <b>250</b>, <b>252</b>. For example, in one embodiment no sealant is provided within housing <b>202</b> (<figref idref="DRAWINGS">FIG. 11</figref>), but sealant (not shown) is provided under one or both boots <b>250</b>, <b>252</b>. Boots <b>250</b>, <b>252</b> are provided to constrain sealant, provide additional sealant to connector <b>200</b>, or provide an entirety of sealant for connector <b>200</b>. In one embodiment, when an inserted conductor is removed from housing <b>202</b>, openings in boots <b>250</b>, <b>252</b> are configured to skive or remove the sealant from the conductor.

0073<figref idref="DRAWINGS">FIG. 12A</figref> is a perspective view of a multi-sided cylindrical electrical connector <b>300</b> according to another embodiment and <figref idref="DRAWINGS">FIG. 12B</figref> is an end view of electrical connector <b>300</b>. Electrical connector <b>300</b> includes a housing <b>340</b>, a conductive member <b>324</b> retained within housing <b>340</b>, and at least two biasing members (one biasing member <b>332</b> is shown) circumferentially disposed within the conductive member <b>324</b>. Biasing member <b>332</b> is configured to urge a conductor inserted into housing <b>340</b> into electrical contact with conductive member <b>324</b>.

0074In one embodiment, housing <b>340</b> provides an electrically insulative cylindrical housing having a plurality of sides and conductive member <b>324</b> provides a cylindrical conductive member <b>324</b> having a plurality of sides retained within the cylindrical housing <b>340</b>. In one embodiment, biasing member <b>332</b> is retained within cylindrical conductive member <b>324</b> along with one or more additional biasing members as shown above in <figref idref="DRAWINGS">FIG. 1B</figref>. Although not required, in one embodiment biasing member <b>332</b> includes a plurality of sides selected to correspond with the number of sides of cylindrical conductive member <b>324</b>. Other geometrical shapes of cylindrical housing <b>340</b>, cylindrical conductive member <b>324</b>, and conical biasing member <b>332</b> are also acceptable.

0075Housing <b>340</b> is suitably formed of the materials described above for housing <b>40</b> (<figref idref="DRAWINGS">FIG. 1A</figref>), conductive member <b>324</b> is suitably formed of the materials described above for conductive member <b>24</b>, and biasing member <b>332</b> includes the biasing members described above in <figref idref="DRAWINGS">FIGS. 7A-10</figref>.

0076An electrical splice connector is provided having a conductive member and two or more biasing members that are configured to urge an inserted conductor into electrical contact with the conductive member. One embodiment of the electrical splice connector includes a cylindrical housing enclosing a cylindrical conductive member that combine to provide improved heat dissipation for the splice connector. Other embodiments provide conical biasing members that bias conductors inserted into the housing into electrical contact with a shared conductive member while minimizing or eliminating column buckling of the inserted conductor.

0077Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of an electrical splice connector as discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.